Sir, We are using Bauxite and Iron ore as flux for type 1 clinker.Now that bauxite is costing more when compared to Iron ore Is it possible to reduce bauxite consumption cosiderably and use iron ore in its place..In that  case to what extent we go down in bauxite consumption and what are all the operational difficulties we  come across??Your valued advice is highly appreciated.

Mohan.M

You can try bauxite's residue, i.e. red mud. It has around 45wt% of hematite and there is a track record of industrial trials in India, China and Greece.

Best regards,

Y. Pontikes 

hello dear 

bauxite and iron ore two different compositions........if you want to reduce the consumption of bauxite , it will be depend upon the chemical analysis of both materials 

As I understand,the optimum requirement of Alumina,Iron,lime and Silica in Type1 clinker is predominantly fullfilled by Bauxite, Iron ore, limestone and Sandstone/Clay respectively.

By reducing bauxite and increasing iron ore modullai values LSF,SM and AM will change and likely to have unfavourable impact on clinker properties such as easy burning mix and tendency for balling in burning zone,unstable kiln and cooler operation and lower strength of clinker

Bhaskar Agate

Thanks all for the valuable information.As you said we faced the same  above problems in kiln operation .

Mohan.M